Three-dimensional composite tiles for use as wall coverings

ABSTRACT

In a three dimensional composite artificial tile formed from a backing sheet of relatively stiff plastic material having a cover sheet of flexible plastic material superimposed on one side of the backing sheet and secured to the periphery thereof, an intermediate layer of resilient material is positioned between the stiff backing sheet and the flexible cover sheet to give the tile a three dimensional appearance.

M 21, 1974 W E. R. POLK 3,311,995

THREE'DIMENSIONAL COMPOSITE FILES FOR USE AS WALL COVERINGS Filed June 27, 1972 United States Patent Office- 3,811,996 Patented May 21, 1974 3,811,996 THREE-DIMENSIONAL COMPOSITE TILES FOR USE AS WALL COVERINGS Edgwin R. Polk, Fords, N.J., assignor to SKF Kugellagerfabriken GmbH, Schweinfurt, Germany Filed June 27, 1972, Ser. No. 266,528 Int. Cl. 1332b 1/04, 3/26, 5/18 US. Cl. 161-44 3 Claims ABSTRACT OF THE DISCLOSURE The present invention relates to artificial tiles and more particularly to tiles which have a three dimensional appearance and which are suitable for use as wall coverings.

A number of tile or panel type wall coverings are presently available for use as wall coverings, however, such wall coverings are generally formed as relatively flat rigid members which have no substantial three dimensional appearance and which provide no insulating or sound deadening effects. Moreover, such tiles and panels are often made of wood or synthetic materials and thus are relatively expensive to manufacture and are diflicult to handle and secure to a wall. In fact, it is generally required that such panels be put up by skilled laborers with the use of special tools or fastening devices in order to insure that the panels are properly mounted on the wall. This, of course, further increases the expense involved with the use of such wall coverings.

Accordingly, it is an object of the present invention to provide a relatively inx-pensive wall covering which creates a three dimensional appearance.

Yet another object of the present invention is to provide a wall covering which is relatively inexpensive to manufacture and simple to install.

Yet another object of the present invention is to provide a wall covering or tile which is relatively durable in use and which provides sound deadening and insulating properties.

In accordance with one aspect of the present invention a three dimensional composite tile structure is provided for use as a wall covering in the home, office, or the like. The tile is formed from a backing sheet of relatively stiff plastic material which, in one embodiment of the invention, is formed of ABS plastic (i.e. acrylonitrile-butadiene-styrene) or rigid PVC (i.e. polyvinylchloride). This type of sheet material is relatively hard and stiff although the material does have the capacity to flex in order to accommodate bends or curves in the wall to which it is secured.

One side of the backing sheet is covered with a flexible sheet material, such as vinyl or the like, which has a generally complementary configuration to the backing sheet and which is secured to the sheet along its periphery. An intermediate layer of a synthetic resilient material, such as a foamed plastic or a synthetic wadding is positioned in superimposed relationship to the backing sheet, between that sheet and the cover sheet, to give the tile a certain amount of body or thickness, and thus a three dimensional appearance, and to provide the tile with sound deadening and insulating properties.

The above, and other objects, features and advantages of the present invention will be apparent in the following detailed description of an illustrative embodiment thereof which is to be read in connection with the single figure of the accompanying drawing which comprises a perspective view of a three dimensional composite tile constructed in accordance with the present invention, with a portion thereof broken away for clarity.

Referring to the drawing in detail, it is seen that a composite three dimensional tile 10, constructed in accordance with the present invention, includes a backing sheet 12, formed of a relatively stifi, plastic material. This sheet, in one embodiment of the invention, is formed of an ABS plastic or rigid PVC and has a certain degree of flexibility to it to permit it to accommodate curves or small bends in the wall to which it is to be secured. It is noted that the term stiff plastic materia as used in this description and in the accompanying claims, is intended to encompass materials such as ABS plastic or rigid PVC which are relatively hard but somewhat flexible.

In the illustrative embodiment of the present invention tile 10 and backing sheet 12 have a generally square configuration, with sheet 12 providing a free peripheral edge 14. Of course, it is to be understood that the tile can take other configurations as desired, including rectangles and even irregular forms.

The upper surface 16 of backing sheet 12 is covered by a flexible sheet 18 of plastic material, such as vinyl or the like, which is slightly larger than backing sheet 12 but has a generally complementary configuration. Sheet 18 has a generally square free edge 20 about its periphery which is secured to the free edge 14 of backing sheet 12. In the preferred embodiment of the invention, free edge 20 of sheet 18 is electronically heat sealed to the edge 14 of sheet 12, although it is contemplated that an appropriate epoxy adhesive or the like could be utilized to provide attachment between the respective peripheries of sheets 12 and 18.

A layer 22 of resilient material is positioned between sheets 12 and 18 and covers substantially the entire surface 16 of sheet 12. This layer of material may be formed of a foamed plastic, such as polyurethane foam or the like, or alternatively, may be formed as a synthetic wadding such as for example, glass or plastic fibrous or strand material. In either case, layer 22 has sufficient thickness so that sheet 18 is fixed relatively tightly around layer 22 to give tile .10 a certain amount of body or thickness and thus a three dimensional appearance.

-In addition, backing sheet 12 is provided with one or more openings 24 therein to provide communication between the interior of the tile and the atmosphere. This permits the tile to breathe so that the surface of the tile, as provided by sheet 18, is relatively flexible and can be depressed upon contact.

By this construction of the invention, tile 10 is conveniently applied to a wall or other surface in any desired manner and preferably by the use of an adhesive. For example, the tile can be provided with a pressure sensitive backing by which it can be secured to a wall, or a separate layer of adhesive can be applied to the wall prior to the application of the tile to the wall with sheet 12 in contact with the adhesive.

Because the top sheet 18 of the tile is formed of a vinyl material, the tile can be constructed with any desired appearance. In one preferred embodiment of the invention, cover sheet 18 is formed to provide a simulated leather appearance so that a wall or other article covered with a plurality of such tiles gives the appearance of a leather covered wall. Of course, cover sheet 18 can be formed with other simulated type surfaces and in a variety of colors.

As a result of the relatively simple construction and light weight of the tile provided by the present invention,

tile 10 is relatively simple and inexpensive to manufacture. Moreover, the tile is simple to install and is easily transported. In addition, because of the use of the resilient layer 22, tile 10 has substantial heat insulating qualities as compared to previously proposed tiles or panels made of solid synthetic or Wood materials and also has substantial sound absorbing or deadening qualities. Accordingly, the tile of the present invention is highly satisfactory for use in ofiices, home studies and the like.

Although an illustrative embodiment of the present invention has been described herein with reference to the accompanying drawing, it is to be understood that various changes and modifications thereof can be made by those skilled in the art without departing from the scope or spirit of this invention.

What is claimed is:

1. A three-dimensional composite tile comprising a backing sheet of relatively hard, plastic material, selected from the group consisting of stifr acrylonitrile-butadienestyrene and rigid polyvinylchloride plastic material, a layer of resilient material selected from the group consisting of a wadding material such as glass fibers and/or foamed plastic superimposed on one side of said backing sheet, and a cover sheet of flexible vinyl material having a configuration generally complementary to said backing sheet, said cover sheet being superimposed on said layer of resilient material and heat sealed along its periphery to the periphery of said backing sheet to contain said layer of resilient material therebetween.

2. The tile as defined in claim 1 wherein said vinyl layer has a simulated leather surface.

3. The tile as defined in claim 2 wherein said backing sheet has at least one opening therein.

References Cited UNITED STATES PATENTS 3,350,257 10/1967 Hourigan et al. 161-43 3,095,943 7/1963 Kemp 16143 X 3,507,727 4/1970 'Marshack 16143 X 3,708,935 1/1973 Kossuth et a1. 16143 X PHILIP DIER, Primary Examiner US. Cl. X.R.

. UNITED STATES PATENT OFFICE QERTEFEQATE Di QGEUHQN Dated May 21 1974 Patent No. 3 811 996 Inventor) Edgwln R. Polk It is certified that error appears in the above-identified patent and that said Letters Patent are hereby corrected as shown below:

On the cover sheet insert [73] Assignee: Packaging Associates, Inc., Elizabeth, N. J.

Signed and sealed this 5th day of November 1974.

(SEAL) Attest:

C. MARSHALL DANN McCOY Mo GIBSON JR. Attesting Officer Commissioner of Patents USCOMM-DC 60376-P69 u.s. GOVERNMENT PRINYING OFFICE: 869 93 0 FORM PO-IOSO (10-69) 

